Sensor module

ABSTRACT

A position sensor module in which a position sensor delivers a signal output to an electronic evaluation unit for further processing, wherein the sensor module and evaluation unit are mounted on and electrically connected by a shaped sheet metal part to eliminate the need for tuning adjustments between the position sensor and the electronic evaluation unit.

[0001] The invention relates to a sensor module in which a position sensor is connected to an electronic evaluation unit which conditions the signal output by the position sensor and corresponding to the position of a component to be monitored.

[0002] In known sensors, the signal output by the sensor is fed to an electronic evaluation unit which conditions the sensor signal for further processing by a connected electronic system. Thus, for example, the signal of a position sensor arranged in a motor vehicle, which represents a variation in the position of a component to be monitored such as the throttle valve, is relayed to an electronic engine management system which generates a control signal for driving the internal combustion engine on the basis of the sensor signal.

[0003] In the electronic evaluation unit, the sensor signal is amplified and an output signal is generated which is corrected in terms of the zero point and/or temperature.

[0004] When the sensor and the electronic evaluation unit are being installed, the two must be tuned to one another. After a preliminary adjustment at the respective manufacturer, the two individual parts must be tuned to one another yet again when being installed in the apparatus which contains the component whose position is to be monitored. Such an adjustment is very complicated. The spatial separation of sensor and electronic evaluation unit requires an additional outlay on wiring.

[0005] It is therefore the object of the invention to specify a sensor arrangement which can be produced simply and with a reduced outlay on adjustment.

[0006] According to the invention, the object is achieved by virtue of the fact that the position sensor and the electronic evaluation unit are jointly arranged at or on a shaped sheet-metal part, the shaped sheet-metal part being designed as a conductor track structure, at least between the sensor and an electronic evaluation unit for the purpose of an electric connection, which conductor track structure is angled off to adapt to the installation site of the sensor.

[0007] The advantage of the invention consists in that accurate placement of the sensor on the component to be monitored is possible owing to the arrangement on a shaped sheet-metal part. It is possible to dispense with connecting lines between the sensor and electronic evaluation unit, thereby reducing the size of the design of the module. The sensor and electronic evaluation unit are adjusted jointly in one step. Not only can a position sensor module thus created be programmed simply in offset and measuring range, but it can also be used for diagnostic purposes such as, for example, to determine a line breakage or short circuit between the sensor and electronic evaluation unit.

[0008] In a preferred embodiment, the sensor is designed as a magnetoresistive sensor which is arranged in a magnetic field.

[0009] The sensor is advantageously arranged approximately at the center of a cylindrically designed permanent magnet. An accurate placement of the sensor in the homogeneous part of the magnetic field is possible owing to the angling-off of the shaped sheet-metal part.

[0010] In an advantageous refinement, the sensor is positioned at a first outer end of the shaped sheet-metal part, the end of the shaped sheet-metal part which projects beyond the electronic evaluation unit in the opposite direction to the sensor being formed by at least one freely ending conductor track of the shaped sheet-metal part. A simple electric connection of the shaped sheet-metal part to other electric circuits is possible in this way.

[0011] In a development of the invention, the free end of the shaped sheet-metal part is electrically connected to a second shaped sheet-metal part, which supports passive electric components and on which the contact device is formed. Because of the use of shaped sheet-metal parts, components required for particular applications can be arranged thereon and connected to one another electrically via the shaped sheet-metal part, and thereby form a compact device which is mounted in vibration-free fashion, particularly for use in motor vehicles. Contact may be made between the two shaped sheet-metal parts with the aid of conventional joining techniques such as welding or soldering.

[0012] The contact device or the free end of the conductor track itself can advantageously be constructed as a plug-in device, it thereby being possible to dispense with the fastening of a separate plug.

[0013] The sensor and the electronic evaluation unit are separately housed in order to protect the sensor and the electronic evaluation unit during installation at the installation site, for example in a motor vehicle.

[0014] In order to produce a position sensor module supplying redundant output signals, a first and a second identically constructed sensor unit respectively consisting of a sensor, a shaped sheet-metal part and an electronic evaluation unit are present, the shaped sheet-metal part of each sensor unit being bent by approximately 90 degrees between the sensor and electronic evaluation unit, and the two sensor units being inserted into the cylindrically designed magnet such that the sensors are arranged lying immediately one above another, while the electronic evaluation units of the two sensor units are arranged decentrally in each case, lying opposite one another, outside the sensor dimensions.

[0015] The invention permits numerous embodiments. One of them is to be explained in more detail with the aid of the figures illustrated in the drawing, in which:

[0016]FIG. 1 shows a first embodiment of the position sensor module according to the invention,

[0017]FIG. 2 shows a second design of the position sensor module according to the invention, and

[0018]FIG. 3 shows a third embodiment of the position sensor module according to the invention.

[0019] Identical features are marked by identical reference numerals.

[0020]FIG. 1 shows a sensor module 1 which consists of a magnetoresistive sensor 12 and an evaluation circuit 13. The sensor 12 is arranged at the end of a lead frame arrangement 14 which is preferably a precision punched frame. The sensor 12 is connected to the evaluation circuit 13 via the fingers 4 a of the lead frame arrangement 14. The evaluation circuit 13 can be connected to other electronic circuit devices via the free ends 14 b of the lead frame arrangement, which project from the evaluation circuit 13 in a direction opposite to the sensor 12.

[0021] The sensor 12 is designed as a magnetoresistive angle sensor and consists of two resistance bridges whose sinusoidal output signals are phase shifted by 90 degrees. The electronic evaluation unit 13 determines the angular position and simultaneously permits compensation of the offset of the angle sensor.

[0022] In the present embodiment, six connections 4 a are provided between the sensor 12, provided with the housing, and the electronic evaluation unit 13, likewise separately housed, while the electronic evaluation unit 13 has five output terminals 14 b for communication with external devices. Like the operating voltage, both control signals and power signals are transmitted via the lead frame connections 14 a and 14 b.

[0023] Because of the connection between the sensor 12 and electronic evaluation unit 13 by means of the punched and bent part 14 a and 14 b, this sensor module 11 can be adapted at will to the installation site at which the fingers 4 a are bent between the sensor 12 and electronic evaluation unit 13, as is to be explained in more detail using the example of FIGS. 2 and 3.

[0024] A redundant system is illustrated in FIG. 2. It consists of two sensor units 1 and 2, which are of identical construction. In this case, the sensor unit 1 consists of the sensor 12, the connections 14 a, the electronic evaluation unit 13 and the terminals 14 b thereof. The second sensor unit 2 likewise consists of a sensor 22 and is connected via the sheet-metal part punched part 24 a to the electronic evaluation unit 23 which, in turn, has sheet-metal punched part 24 b as terminal. The two sensor units 1 and 2 are arranged such that the sensors 12 and 22 lie one on another and the electronic evaluation units 13 and 23 point away from one another.

[0025] The connections 24 a of the second sensor unit 2 between the sensor 22 and evaluation circuit 23 are approximately bent twice by 90 degrees in order for the terminals 14 b and 24 b, respectively, of the two sensor units to lie acceptably in a plane.

[0026] Extending above the sensors 12 and 22 in accordance with the longitudinal direction of the sensor units 1, 2 is a permanent magnet 5 whose magnetic field permeates the sensors 12 and 22, the position-dependent change in the magnetic field being detected by the sensors 12 and 22 and being supplied as output signal to the evaluation circuits 13, 23.

[0027] A further representation of the module according to the invention is illustrated in FIG. 3. Here, the permanent magnet 5 is designed as a cylindrical body, only a portion of this magnet 5 being illustrated in FIG. 3, for the sake of clarity. Arranged at the center of the magnet 5 are the redundant sensor units 1, 2, which consist of the sensors 12 and 22, which are likewise arranged lying one above another. Arranged outside the center, in the vicinity of the wall of the magnet 5, in a fashion opposite one another parallel to the axis of the cylindrical magnet 5, are the evaluation units 13 and 23, whose output terminals 14 b and 24 b respectively, are electrically connected to a printed circuit board 6. The sheet-metal punched part 14 a and 24 a are bent approximately in the vicinity of the sensors 12, 22 by 90 degrees, and thereby enable a very compact, small sensor arrangement.

[0028] Depending on the desired application, the electronic evaluation unit can supply analog or digital output signals, it being possible to trim the electronic evaluation unit for the purpose of temperature compensation. In addition to line breakage and short circuiting between the sensor head and electronic evaluation unit, the electronic evaluation unit can also be used to detect loss of the magnet. Moreover, non-compatible sensor signals can be determined. Monitoring of the evaluation algorithm is possible simultaneously.

[0029] Further lead frames, which contain passive components and/or plug-in elements, can advantageously be fitted at terminals 14 b and 24 b. The overall element can easily be encapsulated by injection molding or processed using conventional joining techniques such as shielded metal arc welding, wave soldering, reflow soldering and/or laser processing. 

1. A sensor module in which a position sensor is connected to an electronic evaluation unit which conditions the signal output by the position sensor and corresponding to the position of an actuator, characterized in that the position sensor (12, 22) and the electronic evaluation unit (13, 23) are jointly arranged at or on a shaped sheet-metal part (14 a, 14 b; 24 a, 24 b), the shaped sheet-metal part (14 a, 14 b; 24 a, 24 b) being designed as a conductor track structure (14 a, 24 a), at least between the sensor (12, 22) and an electronic evaluation unit (13, 23) for the purpose of an electric connection, which conductor track structure is angled off to adapt to the installation site of the sensor (12, 22).
 2. The sensor module as claimed in claim 1, characterized in that the sensor (12, 22) is designed as a magnetoresistive sensor which is arranged in a magnetic field.
 3. The sensor module as claimed in claim 2, characterized in that the sensor (12, 22) is arranged approximately at the center of a cylindrically designed permanent magnet (5).
 4. The sensor module as claimed in claim 1 or 2, characterized in that the sensor (12, 22) is positioned at a first outer end of the shaped sheet-metal part (14 a, 14 b; 24 a, 24 b), and in that the second end of the shaped sheet-metal part (14 a, 14 b; 24 a, 24 b), which project beyond the electronic evaluation unit (13, 23) in the opposite direction to the sensor (12, 22), is formed by at least one freely ending conductor track (14 b, 24 b).
 5. The sensor module as claimed in claim 4, characterized in that the free end (14 b, 24 b) of the shaped sheet-metal part (14 a, 14 b; 24 a, 24 b) is electrically connected to a second shaped sheet-metal part, which supports passive electric components and on which a contact device is constructed.
 6. The sensor module as claimed in claim 5, characterized in that the first and the second shaped sheet-metal parts are welded or soldered.
 7. The sensor module as claimed in claim 4 or 5, characterized in that the contact device or the free end of the conductor track (14 b, 24 b) is constructed as a plug-in device.
 8. The sensor module as claimed in one of claims 1 to 5, characterized in that the sensor (12, 22) and/or the electronic evaluation unit (13, 23) are separately housed.
 9. The sensor module as claimed in one of claims 1 to 5, characterized in that a first and a second identically constructed sensor unit (1, 2) respectively consisting of a sensor (12; 22), a shaped sheet-metal part (14 a, 14 b; 24 a, 24 b) and an electronic evaluation unit (13; 23) are present, the shaped sheet-metal part (14 a, 14 b; 24 a, 24 b) of each sensor unit being bent by approximately 90 degrees between the sensor and electronic evaluation unit, and the two sensor units (1, 2) being inserted into the cylindrically designed permanent magnet (5) such that the sensors (12; 22) are arranged lying immediately one above another, while the electronic evaluation units (13; 23) are arranged decentrally outside the sensor dimensions. 